JABATAN PEMBANGUNAN KEMAHIRAN

KEMENTERIAN SUMBER MANUSIA

ARAS 7 & 8 BLOK D4, KOMPLEKS D
PUSAT PENTADBIRAN KERAJAAN PERSEKUTUAN
62502 PUTRAJAYA

KERTAS PENERANGAN
( INFORMATION SHEET )

KOD DAN NAMA OG-014-3:2012

PROGRAM /
INSTRUMENT PLANT OPERATION
PROGRAM’S CODE &
NAME (OIL, GAS & PETROCHEMICAL)

TAHAP / LEVEL L3

NO. DAN TAJUK UNIT

KOMPETENSI / C03 : TEST EQUIPMENT VERIFICATION
COMPETENCY UNIT
NO. AND TITLE

1. VERIFY TEST EQUIPMENT CALIBRATION &

NO. DAN PENYATAAN
CERTIFICATION
AKTIVITI KERJA /
2. TEST ESD FUNCTIONAL SYSTEM
WORK ACTIVITIES NO.
3. VERIFY INSTRUMENT INSTALLATION SPECIFICATION
AND STATEMENT
4. VERIFY METERING AND CALIBRATION ACTIVITIES

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TITLE: VERIFY TEST EQUIPMENT CALIBRATION & CERTIFICATION

Aim: He / She are responsible in performing verification of Test equipment and instrument
installation as per specification.
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1. Introduction
In general, calibration of equipment needs to be traceable to national standards. When
laboratories use external calibration services, they should obtain a valid certificate from a
calibration laboratory that demonstrates competence, measurement capability and traceability.

A calibration certificate bearing the UKAS (United Kingdom Accreditation Service)

calibration accreditation mark [or identity of the national standards laboratory mark of an
accreditation body with which UKAS has a recognition agreement]for the relevant calibration /
verification will be sufficient evidence. Equivalent to SIRIM, Nucklear Malaysia and accredited
company.

2. Terminology
For the purposes of this publication the following terms apply:
2.1 Calibration: specific types of measurement performed on measurement standards,
material measures and measuring instruments to establish the relationship between the
indicated values and known values of a measured quantity. The term covers calibrations
carried out using appropriate reference equipment at any location.

2.2 Check: specific types of inspection and/or measurement performed on materials and
equipment to indicate compliance or otherwise with stated criteria. The term covers
checks carried out at any location.

2.3 Repeatability : r is the value below which the absolute difference between two or more
single test results obtained with the same method on replicate test samples, under the
same conditions, (same operator, same apparatus, same laboratory and a short interval
of time), may be expected to lie with a specified probability; which, in the absence of
other indicators, is 95%.

2.4 Reproducibility: R is the value below which the absolute difference between two or more
single test results obtained with the same method on replicate test samples, under
different conditions (different operators and/or different apparatus and/or different
laboratories and/or different time), may be expected to lie with a specified probability;
which, in the absence of other indications, is 95%.

2.5 Uncertainty of measurement: a statement of the limits of the range within which the true
value of a measurement is expected to lie at a given level of confidence (see UKAS
publication M3003, The Expression of Uncertainty and Confidence in Measurement).
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 The definitions of r and R are consistent with those given in BSI PD 6461: Part 1:
1995: Vocabulary of Metrology.
3. General
3.1 The laboratories programmed for the maintenance and calibration of equipment will
typically comprise periodic cleaning, servicing, calibration and safety checks (where
applicable). Performance and compliance checks may also be necessary as part of the
calibration aspect of the programed.

3.2 Standards often define the accuracy to be achieved and include specifications for
equipment considered suitable for use. In order to ensure that the equipment available
complies with the requirements of a particular test method, each item must be suitably
calibrated and/or checked. These calibrations and/or checks can be achieved in a
number of ways depending on the parameters being measured, the specified tolerances
and the capability of the laboratory.

3.3 When establishing a calibration programed, aspects of measurement traceability,

procedures, intervals and records for both calibration and checks, need to be
considered for each item of equipment in relation to the particular test method for which
it may be used. These key components are considered in this publication in order to
assist construction materials laboratories establish suitable equipment verification
programed.

3.4 Appendix A lists key items of reference equipment and working equipment used to carry
out a wide range of tests on construction materials, and details a programed of
calibrations and checks which would normally be considered suitable. The table also
indicates the level of traceability generally considered appropriate (see paragraph 4.2),
and for which items external certificates of various forms are advised (see paragraphs
7.2; and 7.6). Appendix A is not an exhaustive list of all items of equipment requiring
periodic recalibration or checking but may be of assistance as a guide when establishing
or reviewing a calibration system.

3.5 It must be borne in mind that the calibration and checking guidance given in this
publication does not supersede the requirements of a nationally published test method
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4. Measurement traceability
4.1 The means of establishing traceability of measurement to national standards will vary
between different items of equipment depending on a number of factors such as the
complexity of the measurement, the accuracy of the measurement, and the capability of
the laboratory.

4.2 Calibrations and checks carried out on equipment used for testing construction materials
and products may be conveniently classified into four general levels as listed below:
 Level 1: A calibration carried out by a laboratory accredited by UKAS for the
measurements concerned and for which a UKAS calibration certificate is
issued. Certificates from other calibration bodies may be acceptable
provided that full traceability to national standards is demonstrated.
 Level 2: A calibration, which may be carried out in-house, performed to a
documented method by competent staff, using appropriate reference
standards / equipment. The reference standards/equipment will need to be
calibrated by a laboratory that can demonstrate competence,
measurement
capability and traceability, e.g. a UKAS accredited calibration laboratory
 Level 3: A check, which may be carried out in-house, performed by competent staff
using appropriately calibrated equipment to a documented procedure.
 Level 4: A visual check, where the item is inspected to provide assurance that the
equipment meets the requirements of the appropriate standard, but no
measurements are required.

4.3 When determining the programed of calibrations and/or checks appropriate for an item
of equipment the capability of the laboratory and requirements of the calibration must be
kept in mind. As a guide, any instrument or reference standard used should have
accuracy 10 times better than that of the device being calibrated. The actual accuracy
required will be determined by calculating uncertainty budgets for particular calibration
regimes using defined calibration apparatus. Guidance on where this should be
performed is given in Appendix A. As an example, a device having a +0.5 % tolerance
might be calibrated using a standard having an uncertainty of +0.05 %. There may,
however, be exceptions to this rule where a factor of 2 or 5 may be acceptable.

4.4 Many items of equipment are assemblies of component pieces of apparatus and
calibrations or checks may be required on the item as a whole, the individual
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components or a combination of both. A number of levels of calibration or check may

therefore be required on the one item.

4.5 Following assessment of a laboratory’s equipment calibration and check system, a

higher level of traceability may be necessary than that undertaken by the laboratory to
achieve the accuracy required in the accredited tests. This situation may arise where the
capabilities required to perform the calibration in-house e.g. environment, equipment,
staff are not available to the laboratory.

5. Calibration and check intervals

5.1 Before equipment is placed into service, a suitable calibration or check is needed to
confirm compliance with the respective standard requirements. Most items of equipment
also require periodic recalibration or checking, as the accuracy or value may change
with use/time. It is important that the recalibration or check is undertaken before any
probable change in accuracy or value has occurred that is of significance to the use of
the equipment. To confirm such changes have not occurred in between recalibration,
interim checks may also be required.

5.2 To assist laboratories develop their calibration and check programed, the table in
Appendix A contains periods between successive calibrations or checks which have
been defined in published standards or are considered to be acceptable. Normally,
these intervals are the maxima acceptable for each specified type of equipment
provided that the equipment:
 is of good quality and known stability;
 has achieved satisfactory performance at previous calibrations and checks;
 is checked before first use or as defined in 5.1, and at appropriate intervals
thereafter to show stability has not been impaired following suspected or indicated
mishandling, overloading or malfunctioning;

5.3 When determining recalibration and check intervals, the applicable test methods in
published standards, UKAS publications and manufacturer’s instructions should be
referred to for initial guidance. The guidance set by these publications and the
compliance of each item of equipment with the criteria detailed under paragraph
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5.4 Will determine the interval finally set. Where there is doubt regarding an individual item’s
ability to meet the above criteria, the calibration/check interval for that piece of
equipment may have to be shortened to ensure continued accuracy and performance. In
some instances this calibration interval may be extended for an individual piece of
equipment e.g. when a stable calibration history has been established. Calibration
intervals may not, however, be relaxed if they are a mandatory element of the test
method

5.5 To ensure that calibrations and checks are carried out at the appropriate frequency a
forward planner should be prepared. A planner may take one of a number of forms. An
all calendar which identifies the items requiring attention in each month, is just one
example of a forward planner. Whatever form the system takes it needs to provide
adequate notice of a pending calibration or check to ensure it is carried out by the due
date. This is particularly important where items are calibrated externally and
considerable time may be required to organize the calibration, to have it carried out and
to evaluate the results before the item is returned to service.

6. Calibration and check procedures

6.1 Laboratories should normally have and follow documented procedures for all
calibrations and checks. [Exceptions may be allowed for measuring equipment when it
is technically unnecessary to require a detailed procedure]. Documented procedures
may be published Standards, instrument manufacturer’s instructions or in-house
procedures. It may be necessary to supplement published procedures with in-house
instructions.

6.2 The appropriate selection and correct execution of these procedures by trained and
authorized personnel is fundamental to achieving confidence in the results of the
calibrations or checks.
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7. Records
7.1 For ease of use, laboratories may wish to hold a number of associated records rather
than one large document or file. A records systems might for instance consist of an
equipment register, calibration/check forward planner and calibration/check and
maintenance files, which may be in hard copy or other suitable laboratory information
management system. It is essential that these records are available to the staff
performing the checks or recalibrations.

7.2 When an external calibration is required (Para 4.2a, Level 1), it is the responsibility of
the laboratory to check each certificate (UKAS or otherwise) in order to ensure that the
corresponding item of equipment is suitable for use. In particular, the certificate must be
checked to ensure that the equipment has been calibrated over the appropriate range
and with the required uncertainty for the test method. Any queries should be raised with
the calibrating body or, where necessary, UKAS.

7.3 The use of preformed record sheets for in-house calibrations or checks (Para 4.2b level
2 and Para 4.2c & d levels 3 & 4) is recommended as this ensures that all necessary
information is recorded. When preparing such preformed, care should be taken to
ensure space is provided for all components of the calibration or check and all
applicable details.

7.4 The use of diagrams and tables indicating acceptable values and actual values may be
useful, particularly where dimensional checks are made. Diagrams may also be helpful
in other areas e.g. to indicate the placement of temperature measuring devices during a
check of the temperature distribution within the working space of an oven.

7.5 Where a simple measurement or visual check of an item is required before each use
(e.g. a visual check of sieves) it is acceptable and often most appropriate to record the
check on the relevant test work sheet rather than on a separate form.

7.6 For some items, parameters, such as the material of manufacture, are specified in the
test method for which calibrations are not required. In such cases, when an item is
purchased, an authoritative certificate or statement of compliance to the design
specification will be needed as evidence that the item is designed and manufactured to
meet the requirements of the test method.
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8. Uncertainty of measurement
8.1 Laboratories testing construction materials are expected to estimate the uncertainty of
measurement for all calibrations carried out in-house (Level 2) on measuring equipment
(i.e. equipment which is used to take measurements such as length, temperature and
mass). Guidance on where this is required is given in Appendix A and typical worked
examples are given in Appendix B. The practicability of this will largely depend on
whether the calibration involves measurements by equipment for which uncertainty
values are available or readily determinable.

8.2 To determine the uncertainty associated with a calibration the procedure should first be
broken down into its component measurements. The significant sources of all
uncertainties should then be identified and quantified. In most cases, uncertainties may
then be combined by an appropriate method to produce an overall uncertainty value.

8.3 Every time a measurement is taken, random effects from various sources contribute
uncertainty to the value of the reading taken. These include variability resulting from
imprecise definition of the calibration (e.g. poor accessibility for taking a length
measurement), uncertainty in discrimination (e.g. interpolation on a scale) and random
fluctuations (e.g. fluctuation in an influencing parameter such as temperature).

8.4 The uncertainties arising from random effects are principally evaluated from repetitive
measurements by statistical methods (a Type A evaluation). Information contained in
Standards on repeatability and reproducibility may be useful when evaluating these
uncertainties.

8.5 Systematic effects also contribute uncertainty, and sources associated with a calibration
include those relating to the equipment used to make each specific measurement and
any peripheral measurements, such as room temperature. The uncertainty associated
with each piece of equipment used to carry out the calibration will in most cases be
available from its current calibration certificate. Where this is not applicable, information
which may be acceptable to UKAS may be available from the equipment manufacturer.
In many cases, it will be practical to eliminate many of the sources of uncertainty, e.g. by
applying corrections from the external calibration report and by carrying out the
calibration at the same temperature at that used for calibrating the reference equipment
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8.6 Appendix B gives worked examples of uncertainty budgets for two commonly used
parameters in materials testing laboratories.

Appendix A
Table detailing calibration and checking of equipment used to test construction materials

A.1 This table has been prepared as a guide to the effective calibration and checking of
items of equipment used to carry out tests on construction materials. Where more than
one type of a particular item is listed (eg reference or working thermometers; coarse
sieves and fine sieves) guidelines are given for each specified type. Note that further
guidance on calibration for specific items may be available. Consult UKAS Publications
(M4) for current UKAS publications.

A.2 The table does not list all items of equipment that may be used and the absence of an
item in the table does not necessarily indicate that calibration or check procedures are
not appropriate
.
A.3 For ease of use, the table is divided into five sections indicating the nature of the
material for which the item is commonly used. These are headed ‘General’, ‘Aggregate’,
‘Bituminous Materials’, ‘Concrete’ and ‘Soils’. Items of equipment are listed
alphabetically within the section to which they relate.

A.4 The table specifically provides guidance on the:

(a) Minimum level of traceability (see Section 4 of this publication), considered
appropriate for each calibration/check;
(b) Maximum period between successive calibrations considered to be appropriate
(see Section 5 of this publication);
(c) The certificates or records of various types that shall be held.
(d) Uncertainty of measurement requirements (see Section 8 of this publication)

A.5 The specified level of traceability is the minimum considered appropriate. An

organization may choose to achieve a higher level of traceability for a calibration/check,
but not a lower one, e.g. Level 1 rather than Level 2.

A.6 The specified calibration interval is the maximum considered appropriate and may not
normally be extended (see Section 5 of this publication).
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A.7 Where the calibration / check requirement for a particular item of equipment (i.e. 3rd
column of table) refers to items of equipment used to carry out the calibration/ check,
many of these auxiliary items are themselves listed as separate entries in the table.

A.8 The relevant parts of the following standard test methods were consulted when
preparing this table.
BS 598 : Parts 102; 105; 107
BS 812 : Parts 100; 101; 102; 103.1; 105.1; 105.2; 109; 110; 111; 112; 113;
114; 118; 120; 121; 124
BS 1377 : Parts 1 – 9
BS 1881 : Parts 101; 102; 103; 105; 106; 107; 108; 112; 114; 115; 116; 117;
118; 119; 120; 122; 125; 127
BS 2000 : Parts 49; 58

Note: These Standards were correct at the time this publication was printed, but calibration
requirements in them may be subject to amendment.

Example Calibration sticker.

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Notes:
1. This Table details recalibration and check intervals, but each item of equipment requires appropriate calibration and /or checking before it is placed
into service.
2. Where a UKAS calibration certificate is indicated by the table, certificates from other sources may be acceptable (see Para 1.3)
3. Where an item is calibrated in-house and is defined as a calibration rather than a check, an uncertainty budget should normally be determined for
that specific calibration procedure. The extreme right-hand column of the table below indicates where an uncertainty budget should be determined.
4. Calibrations must cover the full range for which the equipment is to be used or specified.
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Appendix B
Examples of uncertainty budgets
Example 1 Accuracy of micrometer traverse up to 150 mm using grade 1 gauge blocks

The table below gives all possible input values derived from the calibration of a working
micrometer used to measure lengths up to 150 mm. The micrometer was checked at ten
equally spaced distances in the range of 150 mm using a gauge block or combinations of
gauge blocks to determine the point of maximum inaccuracy, this point was then determined
ten times to give the repeatability (0.5 m). All other values are obtained from the environmental
conditions during the performance of the calibration and the reference equipment used.

Notes
1. 1 The repeatability values given were derived from an internal calibration procedure
being performed under truly repeatable conditions 10 times.
2. The combined standard uncertainty multiplied by coverage factor of k = 2 provides a
confidence level of approximately 95%.
3. References and further reading are given in UKAS publication M3003.
4. The above uncertainty budget is intended to consider all relevant input values, but it is
possible to eradicate some input values, depending on how a calibration is performed
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SOALAN / QUESTION

1. Give 5 following terms applies for purposes of this test equipment calibration.
2. Calibrations and checks carried out on equipment used for testing construction
materials and products may be conveniently classified into four general levels. Gives 2
from 4 levels.